Production of a purified alumina-silica product and substantially pure aluminum trichloride from bauxites and clays

ABSTRACT

At least a two-stage chlorination system for the production of a substantially iron-free alumina-silica product from Bauxites and Clays wherein in a preferred embodiment of the invention the chlorination agent is selected from the group consisting of Cl 2 , HCl and COCl 2  in the first chlorination stage and wherein in the second chlorination stage the chlorination agent is selected from the group consisting of AlCl 3  and SiCl 4 .

BACKGROUND OF THE INVENTION

This invention is primarily applicable to materials such as Bauxites and Clays that have present as major impurities iron and titanium in various mineral forms.

There has been a great deal of research and there is a vast quantity of literature in attempts to produce a relatively iron-free alumina, alumina-silica product and aluminum chloride from such raw materials as Bauxites and Clays. None of the processes proposed have been shown to be economically successful.

This problem can best be described by the following references: Landsberg "Chlorination Kinetics of Aluminum Bearing Minerals:" Metallurgical Transactions B, Volume 6B, June 1975; pps. 207-208. To quote from page 208, 1st column:

"Whereas Foley and Tittle showed that iron could be removed from pre-reduced bauxite by chlorination to produce a refractory grade alumina, FIG. 2 indicates that a substantial loss of alumina accompanies the initial rapid iron chlorination under reducing conditions. Even if this loss could be tolerated the remaining iron is too high for producing cell grade alumina or aluminum chloride."

U.S. Pat. No. 3,842,163, A. S. Russell et al, entitled "Production of Aluminum Chloride" and assignors to Aluminum Company of America, state, to quote lines 45 to 58:

"In general, the reduction of aluminum-containing materials with chlorine in the presence of reducing carbon in some form to produce aluminum chloride is an old and generally well-known reaction and one of the suggested expedients referred to above utilized Bauxite as the alumina containing material. Bauxite however, normally contains many impurities including iron oxide, silica, and titania. Since these impurities readily react with chlorine in the presence of carbon to form iron, silicon, and titanium chlorides, the usual gaseous aluminum chloride reaction effluent therefrom must be subjected to cumbersome and expensive after-purification measures if these chloride contaminants are to be separated to provide even a reasonably pure aluminum product."

The U.S. Department of the Interior, Information Circular i412 by Robert L. de Beauchamp, sums up the problem of producing AlCl₃ from various materials on page 6, the last paragraph reading as follows:

"The raw materials that may be used for the preparation of AlCl₃, include bauxite, clays, shale, anorthosite, coal ash, and many other aluminum containing materials. Bauxite or clays are the most logical choices because of their higher Al₂ O₃ contents and the large reserves of these materials available. Iron is the impurity most deleterious to the process since it uses up chlorine and is difficult to remove from the product."

Canadian Pat. No. 569,830 to Groth in 1939 described a method for chlorinating aluminiferous materials by treating dehydrated and crushed raw materials with aluminum chloride vapor at 600° C.-900° C., removing hot reaction gases containing iron chloride and titanium chloride, treating the residue with chlorine and a reducing agent, and processing the recovered aluminum chloride vapor containing silicon chloride and carbon monoxide at temperatures above 800° C. with alumina or aluminiferous materials free from iron and titanium. The gases recovered from the chlorination process are oxidized to convert at least the chlorides of iron and titanium to their oxides prior to condensation. Therefore, because of the oxidation step, chlorides of the materials are not recovered in reusable form. Further, the vapor mixture recovered cannot be diluted with CO in order that the oxidation stage can be carried out.

Groth Column 1, lines 28 to 32 states:

"It is true that when processing between 900° C.-1150° C. titanium is removed from the original material along with the iron in the form of titanium tetrachloride, but only in small amounts unless a large excess of aluminum chloride is used."

Weston, U.S. Pat. No. 4,277,446, in the first chlorination stage, depends upon the use of excess aluminum chloride containing FeCl₃ that is recovered from the circuit and returned to chlorinate the Fe₂ O₃. To quote, Column 8, lines 30-34

"(b) Excess AlCl₃ that is used is recovered at a low cost as an impure AlCl₃ containing FeCl₃ and returned to the Number One Chlorination Stage without any deleterious effects on chlorinating the contained iron and titanium minerals."

Most surprisingly I have found that with the present invention the removal of the Fe₂ O₃ from the raw material is far more effective than from either the teachings of Groth or Weston and in effect, as shown in the examples, has been reduced to a level which to the inventor's knowledge, has never been achieved heretofore by differential chlorination.

SUMMARY OF THE INVENTION

It is accordingly a primary object of the present invention to provide a novel and low cost process for the production of aluminum-silicon products substantially free of iron.

A further object of the present invention is to provide a novel and low cost process for the production of a substantially pure aluminum trichloride from Bauxites and Clays wherein the iron has previously been removed from the raw materials prior to mass chlorination with Cl₂ or COCl₂ to produce aluminum trichloride.

In satisfaction of the foregoing objects and advantages there is presented by this invention in its broadest concept a process for the production of a substantially iron free alumina-silica product, and substantially pure aluminum trichloride from various materials containing aluminum in the form of aluminum oxide minerals and complex aluminum minerals such as Kaolinite, that is Al₂ O₃. 2SiO₂.2H₂ O, the process comprising:

(a) Calcining the feed material prior to the first chlorination stage to remove free and chemically combined water, and where such minerals as Kaolinite are present to break the chemical bond of Al₂ O₃, SiO₂, and H₂ O, driving off the H₂ O as water vapor and forming amorphous Al₂ O₃ and amorphous SiO₂, which products respond differentially to chlorination treatment.

(b) Number One Chlorination Stage in which the agents are at least CO and at least an agent selected from the group consisting of Cl₂, COCl₂ and HCl and optionally from the group consisting of SiCl₄ and AlCl₃.

Most surprisingly, I have found that by the use of minor or starvation quantities of these groups of agents in a first chlorination stage at least 90% of the contained iron in the raw material can be differentially chlorinated and when followed by a second differential chlorination stage using minor or starvation quantities of agent selected from the group consisting of AlCl₃ and SiCl₄ at least 99% of the original contained iron in the raw material is chlorinated and removed. The temperature is this Number One Chlorination Stage is about 750° C. to about 1150° C.

(c) Number Two Chlorination Stage in which the agents are at least CO and at least agent selected from the group consisting of AlCl₃ and SiCl₄. The temperature range is about 900° C. to about 1150° C.

The end solids product from this Number Two Chlorination Stage will be Al₂ O₃ and SiO₂ substantially free of Fe₂ O₃ and highly desirous by the refractories industry.

(d) This end solids product may be further treated in a Number Three Chlorination Stage to produce a substantially iron free AlCl₃ by means well known to the Art using at least agents selected from the group consisting of Cl₂ and COCl₂. The AlCl₃ is feed stock to the fused salt electrolytic cell for the production of aluminum metal.

If the contained iron in the feed material to the process is not removed prior to this Number Three Chlorination Stage normally a substantial portion of it will chlorinate under the Number Three Chlorination Stage conditions and finally report in the aluminum metal produced which is unacceptable in the production of a relatively pure aluminum metal. All of the steps described beginning with the Calcination Stage may be carried out in fluo-solids reactors well known in the Art.

The following will define for clarity various terms used in describing the invention:

Calcination--also known as dehydration--this terminology as used in this application means the following:

(a) Removal of any free moisture as steam.

(b) Breaking down of the bond of water of crystallization in aluminum oxide minerals having the chemical analysis of Al₂ O₃.xH₂ O, wherein a high percentage of water of crystallization is driven off as steam.

(c) Breaking down of the chemical bond or bonds of complex aluminum minerals such as Kaolinite, Al₂ O₃.2SiO₂.2H₂ O, wherein the H₂ O is driven off as steam and the Al₂ O₃ and SiO₂ are converted into amorphous Al₂ O₃ and amorphous SiO₂ respectively. To accomplish satisfactory calcination of Bauxites and Clays, a temperature range of 625° C. to about 1100° C. may be used. It will be appreciated that the effectiveness of the calcination step is a primary function of temperature and time, the economic optimum being readily determined by anyone skilled in the Art.

This stage of the process uses conventional equipment well known in the Art, and consists of such equipment as horizontal rotary kilns, vertical shaft furnaces, and fluo-solids reactors with their auxiliary gas scrubbers and dust collection units.

Clays--generally refer to materials containing little or no Al₂ O₃.xH₂ O minerals and the major aluminum mineral component is essentially Kaolinite.

Iron and Titanium--the standard practice of the aluminum industry is to report Fe and Ti analyses as Fe₂ O₃ and TiO₂. The iron and titanium minerals contained in the aluminum bearing materials vary considerably and are but rarely only in the form of Fe₂ O₃ and TiO₂. For instance the major iron mineral in Arkansas Bauxite is siderite, FeCO₃, and the commonest occuring form of titanium is as ilmenite, FeOTiO₂. When I refer to percentages of Fe₂ O₃ and TiO₂ herein, I mean the chemical analyses of Fe and Ti converted to Fe₂ O₃ and TiO₂ respectively.

Carbon--any form of carbon that can be used in specific stages of the process of the invention as a reducing agent for the contained metallic oxides in the raw material used in the process herein described, and that will not introduce added impurities that may have a major detrimental effect on the final desired product.

Examples of such carbon are charcoal, devolatilized coal coke, and devolatilized petroleum coke. The type of coke used should be carefully selected to avoid introducing comparatively large quantities of impurities that may have a major detrimental effect in the process to produce pure aluminum trichloride.

Devolatilization--refers to solid fuels such as coal or petroleum coke wherein the specific material has been heated to a sufficiently high temperarture to drive off substantially all of the contained water as water vapor and any free hydrogen contained in the raw material.

Neutral conditions--where there is just sufficient free oxygen to meet the needs of the reaction.

Oxidizing conditions--where there is an excess of free oxygen to meet the needs of the reaction and free oxygen present at the end of the particular stage.

Reducing conditions--where there is an excess of free carbon, CO, H₂, or CH radical present to meet the needs of the reaction.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the drawings accompanying the application where it will be seen that

FIG. 1 shows a preferred flowsheet of the invention for the production of an alumina-silica product substantially free of iron and the further treatment of this product to produce aluminum trichloride substantially free of ferric chloride and as feed stock for the production of substantially pure aluminum metal.

FIG. 2 shows a preferred flowsheet of the invention treating the gaseous product produced by Number Three Chlorination Stage by passing the gaseous product through a charcoal or devolatilized coke bed to convert the contained CO₂ to CO.

The gas stream containing the CO, and after removal of the aluminum chloride, (not shown) is preferably cycled to the numbers one and three chlorination stages.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a preferred flowsheet of the invention. The prepared feed material shown at 11 may have been pretreated by magnetic cobbing to remove part of the Fe₂ O₃ and where present ilmenite and biotite mica. Where ultra fines are present the feed material may have been granulated or pelletized by conventional means to prevent losses in the gas streams during calcination or chlorination particularly when using fluo-solids reactors.

The feed material is fed to the Calcining Stage 12 to remove free moisture and water of crystallization. The equipment is conventional (not shown) consisting of such units as horizontal kilns, shaft furnaces, and fluo-solids reactors. In the calcination stage 12 and in the at least three chlorination stages shown at 13, 14 and 19 my preferred equipment (not shown) is fluo-solids ractors. From the Calcination Stage the material is fed to the Number One Chlorination Stage shown at 13. In this stage as much as 98% of the Fe₂ O₃ in the material is differentially chlorinated with but minor to negligible amounts of the contained Al₂ O₃. The solids product from the Number One Chlorination Stage is fed to the Number Two Chlorination Stage Shown at 14 wherein the Fe₂ O₃ in the feed material is further differentially chlorinated with negligible or no chlorination of the contained alumina and raising the differentially chlorinated Fe₂ O₃ to in excess of 99% of the original feed material.

The solids product shown at 15, 17 and 18 normally analyzing less than 0.01% Fe₂ O₃, is an unheard of purity for use in the refractory industry where the limiting Fe₂ O₃ specification is of utmost importance.

Where it is desirous to produce an aluminum chloride product substantially free of iron the solids product 15 is fed to the Number Three Chlorination Stage shown at 19. This stage involves mass chlorination of the contained alumina normally using large concentrations of Cl₂ either as Cl₂ or COCl₂ and in the presence of reducing agent preferrably selected from the group consisting of C and CO.

The solids product shown at 20 consists of amorphous silica and minor amounts of alumina and is either a waste product or maybe marketed as, primarily, filler.

The gaseous product shown at 21 will contain the desired aluminum chloride plus minor amounts of SiCl₄, TiCl₄, Cl₂, CO₂ and CO, and trace amounts of FeCl₃.

As the volatilization temperatures of the AlCl₃, SiCl₄ and TiCl₄ are 183° C., 59° C. and 137° C. respectively there is no problem in their separation from each other and from the CO₂, CO and Cl₂.

The FeCl₃ has a vapor solubility in the AlCl₃ and thus it is of the utmost importance to reduce the Fe₂ O₃ in the feed material to the Number Three Chlorination Stage to the lowest possible level which in the invention has been demonstrated to be less than 0.01% or in excess of 99% of the original Fe₂ O₃ contained in the feed material.

FIG. 2 shows a preferred flowsheet of the invention treating the gaseous product from Number 3 Chlorination Stage. The gaeous product shown at 22 is passed through one or more beds of charcoal or devolatilized coke shown at 28 to convert CO₂ contained in the gas stream to CO. The gas stream discharging from the treatment stage is either treated by differential temperature condensation or fractional distillation or a combination of the two as shown at 29, and well known to the Art, to produce as shown at 30 substantially pure AlCl₃ which is a saleable product in itself or may be fed to a fused salt electrolytic bath to produce aluminum metal and the contained chlorine released and returned to the Number Three Chlorination Stage. In addition the SiCl₄ may be sold as a commercial product with at least part cycled to the Numbers 1 or 2 or both chlorination stages. The TiCl₄ can be converted to either titania or titanium metal. The CO and Cl₂ remaining in the gas stream are preferably cycled to Numbers one and 3 chlorination stages. The gas stream discharging from the Number One Chlorination Stage (not shown) is preferably cycled to the Number Two Chlorination Stage to primarily maintain the reducing conditions with CO.

An alternate circuit shown at 23 to 27 separates the AlCl₃, SiCl₄ and TiCl₄ from the CO₂, CO, and Cl₂ prior to conversion of the CO₂ to CO. In a preferred embodiment (not shown) the SiCl₄ is retained in the gas stream with the CO and Cl₂ thus supplying the requisite SiCl₄ to the Number One Chlorination Stage.

EXAMPLES OF THE INVENTION

The following examples of the invention were carried out on a bulk sample of Kaolinitic Clay from a deposit located in the south eastern United States of America.

The sample as received was magnetically cobbed in a Colburne laboratory high intensity magnetic laboratory unit, dried to approximately 5% free moisture, crushed, put through a rolls and screened at 10 mesh and 100 mesh to produce a product that was essentially minus 10 plus 100 U.S. Standard. This product was calcined at 700° C. to 750° C., and after calcination was the feed material to the following examples except where otherwise noted.

The chemical analysis of the calcined product was as follows:

    ______________________________________                                         Al.sub.2 O.sub.3                                                                         SiO.sub.2                                                                             Fe.sub.2 O.sub.3                                                                            TiO.sub.2                                                                           L.O.I.                                      ______________________________________                                         44.0      51.5   1.27         2.77 0.3                                         ______________________________________                                    

All of the examples were carried out in a 21/2 inch fluo-solids reactor using batch charges of 250 grams.

The total gas volume used in all tests was kept reasonably constant at 5.0 liters per minute calculated at 21.1 C., and adjusted to the 5.0 liters with CO.

EXAMPLE 1

The following were conditions of this example:

Temperature in stages one and two, 1010° C.

CO in both stages, adjusted to total gas volume of 5.0 liters/min.

Stage 1--SiCl₄ 0.7 gms/min. for 20 mins.

Stage 2--AlCl₃ 4.9 gms/min. for 40 mins.

The following results were obtained:

    ______________________________________                                                  Chemical                                                                       Analysis Solids                                                                             Gases                                                             % by Weight  % Distribution                                           Stage No.  Fe.sub.2 O.sub.3                                                                       TiO.sub.2  Fe.sub.2 O.sub.3                                                                     TiO.sub.2                                  ______________________________________                                         1          0.021   0.494      98.35 82.1                                       2          0.012   0.273      99.05 90.15                                      ______________________________________                                    

In Stage 1 the SiCl₄ formed only approximately 2.0% of the gas stream and differentially chlorinated 98.35% of the Fe₂ O₃ and 82.1% of the TiO₂. All of the SiCl₄ could be chemically accounted for in the reactions with the Fe₂ O₃ and TiO₂ resulting in no requirement for recirculation of any excess chlorination agent such as in the Weston U.S. Pat. No. 4,277,446.

This was an amazing result in a twenty minute differential chlorination period.

The following are the chemical reactions involved:

    2Fe.sub.2 O.sub.3 +3SiCl.sub.4 →4FeCl.sub.3 +3SiO.sub.2

    TiO.sub.2 +SiCl.sub.4 →TiCl.sub.4 +SiO.sub.2

In using CO as the main fluidizing agent the outstanding metallurgy using SiCl₄ as the chlorination agent could not be duplicated using CO₂.

Further, in using appreciably higher concentrations of SiCl₄ the results could not be duplicated. There seems to be no logical explanation for this totally unexpected phenomenon.

The maximum concentration of SiCl₄ in the gas stream for optimum results is approximately 10%.

In Stage 2 of the process the final product shows 99.05% of the Fe₂ O₃ and 90.25% of the TiO₂ differentially chlorinated.

Not only does this product meet unheard of Fe₂ O₃ specifications for the highest grade refractory, but in addition, following mass chlorination of the contained Al₂ O₃ and differential temperature condensation of the AlCl₃ would produce acceptably pure aluminum metal.

In this stage 2 the AlCl₃ was approximately 6.5% of the gas stream, which was approaching the maximum for optimum results.

As in Stage 1 the phenomenon of comparatively low chlorination agent concentrations for optimized metallurgy is not understood nor does there seem to be any logical explanation.

EXAMPLE 2

The following were conditions of this example:

Temperature Stage 1, 913° C. and Stage 2, 1029° C.

CO in both stages adjusted to total gas volume of 5.0 liters/min.

Stage 1--SiCl₄ 0.94 gms/min. plus HCl 1.5 gms/min. for 15 mins.

Stage 2--AlCl₃ 4.53 gms/min. for 45 mins. The following results were obtained:

    ______________________________________                                                  Chemical                                                                       Analysis Solids                                                                             Gases                                                             % by weight  % Distribution                                           Stage No.  Fe.sub.2 O.sub.3                                                                       TiO.sub.2  Fe.sub.2 O.sub.3                                                                     TiO.sub.2                                  ______________________________________                                         1          0.016   2.01       98.7  27.5                                       2          0.004   0.31       99.7  88.8                                       ______________________________________                                    

In using the combination of SiCl₄ and HCl in Stage 1 followed by minor amounts of AlCl₃ in Stage 2 the differential chlorination of 99.7% of the Fe₂ O₃, to the inventor's knowledge, has never heretofore been accomplished.

The SiCl₄ used was approximately 2.7% of the gas stream; the HCl was approximately 18% of the gas stream for a total concentration of chlorination agent in the gas stream of about 21%.

In Stage 2--the AlCl₃ was approximately 15% of the gas stream.

EXAMPLE 3

The following were conditions of this example.

Temperature Stage 1, 850° C. and Stage 2, 975° C.

CO in both stages adjusted to total gas volume of 5.0 liters/min.

Stage 1--HCl 1.5 gms/min. for 30 mins.

Stage 2--AlCl₃ 4.46 gms/min. for 60 mins.

The following results were obtained:

    ______________________________________                                                  Chemical                                                                       Analysis Solids                                                                             Gases                                                             % by weight  % Distribution                                           Stage No.  Fe.sub.2 O.sub.3                                                                       TiO.sub.2  Fe.sub.2 O.sub.3                                                                     TiO.sub.2                                  ______________________________________                                         1          1.02    2.17       19.7  21.7                                       2          0.009   0.65       99.3  76.5                                       ______________________________________                                    

In Stage 1 the chlorination agent HCl formed approximately 18% of the gas stream. It will be noted that HCl by itself is a poor chlorination agent. However, when it is followed in a second chlorination stage by AlCl₃ the differential chlorination of the Fe₂ O₃ is outstanding. SiCl₄ may be used in place of the AlCl₃ particularly in the production of premium grade refractory.

EXAMPLE 4

The following were conditions of this example.

Feed material--minus 18+100 mesh.

Temperature Stage 1--925° C., Stage 2--1010° C. and Stage 3--1010° C.

CO in all Stages adjusted to total gas volume of 5.0 liters/min.

Stage 1--Cl₂ 0.6 gms/min. plus HCl 0.3 gms/min for 20 mins.

Stage 2--AlCl₃ 1.5 gms/min. for 40 mins.

Stage 3--Cl₂ 8.8 gms/min. for 60 mins. plus 27 gms. NaCl, 12 gms, KCl and 40 gms. wood charcoal to the reactor charge.

The following results were obtained:

    ______________________________________                                                 Chemical Analysis Solids                                                                       Gases                                                          % by weight     % Distribution                                         Stage No. Fe.sub.2 O.sub.3                                                                         TiO.sub.2     Fe.sub.2 O.sub.3                                                                     TiO.sub.2                              ______________________________________                                         1         0.020     1.928         98.4  30.5                                   2         0.007     0.629         99.4  77.5                                   3         SiO.sub.2        71.35                                               ______________________________________                                    

In Stage 1 the chlorination agent Cl₂ and HCl formed approximately 4% and 3.7% of the total gas stream respectively.

In Stage 2 the chlorination agent AlCl₃ formed approximately 7% of the total gas stream.

In Stage 3 the chlorination agent Cl₂ for the chlorination of the contained Al₂ O₃ in the feed material was approximately 60% of the gas stream. The outstanding differential chlorination of the Fe₂ O₃ in Stages 1 and 2 using the combination of starvation amounts of Cl₂ and HCl in Stage 1 and minor amounts of AlCl₃ in Stage 2 is noteworthy. In Stages 3 mass chlorination of the contained Al₂ O₃ was illustrated with the use of CO and C as reducing agents, NaCl and KCl as catalysts, and Cl₂ as the chlorination agent.

In my preferred circuit for the final production of AlCl₃ following at least the removal of the Fe₂ O₃ my preferred catalysts are NaAlCl₄ and KAlCl₄.

Where I use this Stage 3, I prefer to pass the gas stream from this circuit through either a charcoal or devolatilized coke bed converting the contained CO₂ in the gas stream to CO with the excess CO thus produced to Stages 1 and 3.

EXAMPLE 5

The followign were conditions of the example:

Feed material--minus 18 plus 100 mesh.

Temperature Stage 1--925° C. Stage 2--1010° C. and Stage 3--1010° C.

CO in all stages adjusted to total gas volume of 5.0 liters/min.

Stage 1--Cl₂ 0.79 gms/min. for 20 mins.

Stage 2--AlCl₃ 1.0 gms/min. for 40 mins.

Stage 3--Cl₂ 8.8 gms/min. for 60 mins., plus 40 gms. wood charcoal, 18 gms. NaCl and 18 gms. KCl to bed in reactor.

The following results were obtained:

    ______________________________________                                                 Chemical Analysis Solids                                                                       Gases                                                          % by weight     % Distribution                                         Stage No. Fe.sub.2 O.sub.3                                                                         TiO.sub.2     Fe.sub.2 O.sub.3                                                                     TiO.sub.2                              ______________________________________                                         1         0.022                   98.3                                         2         0.009                   99.3                                         3         0.009     0.262         99.3  90.5                                             SiO.sub.2        72.56                                               ______________________________________                                    

In Stage 1 the chlorination agent Cl₂ formed approximately 4.5% of the total gas stream. In Stage 2 the chlorination agent AlCl₃ formed approximately 5.0% of the total gas stream.

The outstanding differential chlorination of the Fe₂ O₃ in Stages 1 and 2 using starvation amounts of Cl₂ in Stage 1 and starvation amounts of AlCl₃ in stage 2 in the presence of CO is noteworthy. As in Example 4, mass chlorination of the contained Al₂ O₃ was illustrated in stage 3.

In Stage 1 of the Process the minimum temperature is about 750° C. and the maximum about 1150° C.

In Stage 2 of the Process the minimum temperature is about 900° C. and the maximum about 1150° C.

In Stage 3 of the Process the minimum temperature is about 750° C. and the maximum about 1150° C.

It will be noted that in the two-stage chlorination systems hereindescribed, the combination of chlorination agents used to produce a substantially iron free alumina silica product are, to the inventor's knowledge, new to the art with no logical explanation for the highly efficient differential chlorination of the iron contained in the feed material.

The invention has been described herein with reference to certain preferred embodiments. However, as obvious variations thereon will become apparent to those skilled in the Art, the invention is not considered limited thereto. 

What I claim as my invention is:
 1. A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al₂ O₃.2SiO₂.2H₂ O and said bauxites contain at least one of the minerals with the chemical analysis of Al₂ O₃.x2H₂ O and at least one silica mineral from the group consisting of Al₂ O₃.2SiO₂.2H₂ O and SiO₂ and said group of raw materials contain at least iron as iron mineral, the said process comprising:(a) subjecting the said raw material to at least a calcining stage wherein the said mineral is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al₂ O₃.2SiO₂.2H₂ O and said Al₂ O₃.xH₂ O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage to differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is at least one member selected from the group consisting of Cl₂, HCl, and COCl₂ and in the presence of at least CO and in the temperature range of about 750° C. to about 1150° C. and said chlorination agent forms less than about 21% of said gas stream to produce a said solids alumina-silica product impoverished in said iron; and (c) subsequently subjecting the said solids alumina-silica product to a number two chlorination stage to further differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is selected from the group consisting of SiCl₄ and AlCl₃ and in the presence of at least CO and in the temperature range of about 900° C. to about 1150° C. and said chlorination agent being present in minor amounts of said gas stream to produce a said solids alumina-silica product further impoverished in said iron.
 2. The process of claim 1 wherein in the said number one chlorination stage the said chlorination agent is Cl₂.
 3. The process of claim 1 wherein in the said number one chlorination stage the said chlorination agent is Cl₂ and HCl.
 4. A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al₂ O₃.2SiO₂.2H₂ O and said bauxites contain at least one of the minerals with the chemical analysis of Al₂ O₃.xH₂ O and at least one silica mineral from the group consisting of Al₂ O₃.2SiO₂.2H₂ O and SiO₂ and said group of raw materials contain at least iron as iron mineral, the said process comprising:(a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al₂ O₃.2SiO₂.2H₂ O and said Al₂ O₃.xH₂ O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage to differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is SiCl₄ and at least one member selected from the group consisting of Cl₂, HCl, and COCl₂ and in the presence of at least CO and in the temperature range of 750° C. to about 1150° C. and said chlorination agents form less than about 21% of said gas stream to produce a said solids alumina-silica product impoverished in said iron; and (c) subsequently subjecting the said solids alumina-silica product to a number two chlorination stage to further differentially chlorinate the said iron and said chlorination is carried out by a gas stream wherein the chlorination agent is selected from the group consisting of SiCl₄ and AlCl₃ and in the presence of at least CO and in the temperature range of about 900° C. to about 1150° C. and said chlorination agent being present in minor amounts of said gas stream to produce a said solids alumina-silica product further impoverished in said iron.
 5. The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl₄ and Cl₂.
 6. The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl₄ and HCl.
 7. The process of claim 4 wherein in the said number one chlorination stage the said chlorination agent is SiCl₄, Cl₂ and HCl.
 8. A process for the production of a substantially iron free alumina-silica product from the group of raw materials consisting of kaolinitic clays and bauxites wherein said kaolinitic clays contain at least kaolinite with the chemical analysis of Al₂ O₃.2SiO₂.2H₂ O and said bauxites contain at least one of the minerals with the chemical analysis of Al₂ O₃.xH₂ O and at least one silica mineral from the group consisting of Al₂ O₃.2SiO₂.2H₂ O and SiO₂ and said group of raw materials contain at least iron as iron mineral, the said process comprising:(a) subjecting the said raw material to at least a calcining stage wherein the said material is heated to within the temperature range of 625° C. to about 1150° C. to remove free moisture and water of crystallization combined in said minerals contained in the said material and to convert said Al₂ O₃.2SiO₂.2H₂ O and said Al₂ O₃.xH₂ O to alumina and silica to produce a calcined solids alumina silica product containing said iron; (b) subsequently subjecting the said calcined product to a number one chlorination stage wherein the chlorination agent is SiCl₄ and wherein the said SiCl₄ forming part of the said chlorination stage gas stream is in the range of about 2% to 10% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a chlorinated said solids alumina-silica product impoverished in said iron; (c) subsequently subjecting the said solids product to a number two chlorination stage wherein the chlorination agent is AlCl₃ and wherein the said AlCl₃ forming part of the said chlorination stage gas stream is in the range of about 5% to 20% of said gas stream and in the presence of at least CO and in the temperature range of about 900° C. to 1150° C. to produce a further chlorinated said solids alumina-silica product substantially free of said iron.
 9. The process of claim 1, 4 or 8 wherein subsequent to the said number two chlorination stage said solids alumina-silica product substantially free of iron is subjected to a number three chlorination stage wherein the said chlorination agent is at least selected from the group consisting of Cl₂ and COCl₂ and in the presence of reducing agent selected from the group consisting of C and CO and in the temperature range of about 750° C. to 1150° C. to chlorinate the said alumina and wherein the resultant gas stream following said chlorination stage is substantially free of said iron and the said C and CO is substantially converted to CO₂, and the said alumina is substantially converted to aluminum chloride, and wherein in reducing the temperature of said gas stream to below 183° C. to condense the said aluminum chloride and produce a substantially iron free aluminum chloride product.
 10. The process of claim 9 wherein the condensation of aluminum chloride is carried out between about 183° C. and above 137° C.
 11. The process of claim 9 wherein the said resultant gas stream is passed through a bed selected from the group consisting of charcoal and devolatilized coke to convert the said CO₂ to CO.
 12. The process of claim 9 wherein subsequent to the production of the said aluminum chloride product the remaining said gas stream is passed through a bed selected from the group consisting of charcoal and devolatilized coke to convert the said CO₂ to CO.
 13. The process of claim 1, 4, or 8 wherein subsequent to the said number two chlorination stage said solids alumina-silica product substantially free of iron is subjected to a number three chlorination stage wherein the said chlorination agent is at least selected from the group consisting of Cl₂ and COCl₂ and in the presence of reducing agent selected from the group consisting of C and CO and in the temperature range of about 750° C. to 1150° C. and in the presence of at least one catalyst selected from the group consisting of NaCl, KCl, NaAlCl₄ and KAlCl₄ to chlorinate the said alumina and wherein the resultant gas stream following said chlorination stage is substantially free of said iron and the said C and CO is substantially converted to CO₂ and the said alumina is substantially converted to aluminum chloride, and wherein in reducing the temperature of said gas stream to below 183° C. to condense the said aluminum chloride and produce a substantially iron free aluminum chloride product. 